DIY Custom Oversized ΔΤΔ Fraternity Letters - April 2025

Overview

This project involved designing, building, and painting 48" tall ΔΤΔ letters for chapter events, tailgates, recruitment, and general signage. The goal of this project was to build large, visually appealing, weather-resistant signs while spending less than $100.

48" is the size I chose, as it’s the largest size we could cut from a 4' by 4' sheet of material. While I could have used scraps to increase the letter size, this would have required brackets of some sort and added complexity. Thus, I stuck with a 48" size. For the material, I used 3/4" MDF, as it was sturdy and the cheapest 4' x 4' option available at Home Depot.

I used a photo I found online as a guide to mark out the ΔΤΔ letters. The Deltas were straightforward and just required two lines from the bottom edges that meet at the middle of the top edge. I opted to make the “bodies” of the Delta letters 8" wide. I then visually compared the proportions of the letters online and used those same ratios in my outline drawings so that the scaled serifs would still look good. I used a straightedge and a pencil compass while marking to keep everything as precise as possible.

I cut the Deltas using a table saw, as that allowed for quick, easy, and very straight cuts. The Tau required a jigsaw, as it had many curved sections that the table saw couldn’t handle. For straight sections, I clamped a level to the MDF to guide the jigsaw. For curved sections, I carefully guided the jigsaw along, keeping it aligned with the cut line. Overall, the cutting process went smoothly, largely due to thorough preparation.

For paint, I used Behr Premium outdoor paint in Royal Purple and Brilliant White, as these best matched ΔΤΔ colors. I applied a basic KILZ primer and used materials from the CU Boulder ITLL to facilitate the painting process. I chose purple letters with 1.5" white outlines. The letters received three coats of primer on each side, three coats of purple base, and two coats of white outline. I finished the signs with a can of Rust-Oleum satin clear coat to improve weather resistance. While I only primed the backs of the letters, I did apply clear coat to the backs as well to keep them fully sealed.

Overall, I'm very happy with how the letters turned out, and I can't wait to see them hung up at the house.

Process

• Planning: Measured available MDF sheets and laid out full-scale designs using a projector and pencil.
• Cutting: Rough cuts made with a table saw to manage large pieces; detailed shapes cut using a jigsaw.
• Sanding: All edges sanded smooth using an orbital sander followed by hand sanding for detail work.
• Painting: Each letter was primed and then painted using three coats of exterior paint — a purple base color and a white accent color for outlining.
• Sealing: Finished letters were sealed with a protective clear coat to withstand outdoor use.

What I Learned

• Selecting materials that meet durability requirements while also meeting a set budget
• Identifying ideal tools for specific tasks like cutting curves
• How to prep and paint for best finish and superb weather resistance